Method of manufacturing an optical lens

ABSTRACT

A method of manufacturing an optical lens that is configured to correct high order aberrations. One embodiment is a method of customizing optical correction in an optical system. The method includes measuring optical aberration data of the optical system. The method further includes calculating a lens definition based on the optical aberration data. Calculating the lens definition may include calculating a correction of at least one high order optical aberration. The method further includes fabricating a correcting lens based on the lens definition.

RELATED APPLICATIONS

This application claims the benefit of, and incorporates by reference,U.S. Provisional Application No. 60/520,065 filed Nov. 14, 2003. Thisapplication also claims the benefit of, and incorporates by reference,U.S. Provisional Application No. 60/546,378, filed on Feb. 20, 2004.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to systems and methods relating tomanufacturing customized optical lenses for correcting aberrations ofoptical systems such as the human eye.

2. Description of the Related Art

The human eye, namely the cornea and lens, can exhibit a variety ofoptical aberrations that diminish the optical performance of the eye,resulting in blurred vision. The correction of blurred vision by fittingpatients with lenses has typically been limited to the correction of loworder aberrations only, such as defocus and astigmatism. Traditionally,high order aberrations, e.g. those describable with Zernike polynomialsof the third order or higher, could not be corrected using lenses. Inaddition, due to lens manufacturing limitations and expenses, defocusand astigmatism are typically only corrected in discrete steps, with anycorrection being made to the nearest one quarter (0.25) diopter (D).Unfortunately, the resolution of one quarter (0.25) diopter results inincomplete vision correction.

SUMMARY OF CERTAIN INVENTIVE ASPECTS

The system, method, and devices of the invention each have severalaspects, no single one of which is solely responsible for its desirableattributes. Without limiting the scope of this invention as expressed bythe claims which follow, its more prominent features will now bediscussed briefly. After considering this discussion, and particularlyafter reading the section entitled “Detailed Description of CertainEmbodiments” one will understand how the features of this inventionprovide advantages that include convenient and economical methods ofmanufacturing optical lens and lens blanks.

One embodiment is a method of customizing optical correction in anoptical system. The method includes measuring optical aberration data ofthe optical system. The method further includes determining, based onthe optical aberration data, a lens definition including a correction ofat least one high order optical aberration. The method further includesfabricating a correcting lens based on the lens definition.

Another embodiment is a method of manufacturing a customized lens. Themethod includes measuring optical parameters of an optical system. Theoptical parameters may include measured optical aberrations. The methodfurther includes forming a lens having at least one optical element.Forming the lens may include correcting a portion of the measuredoptical aberrations in the at least one optical element. The portion mayinclude at least one low order aberration. Forming the lens may furtherinclude correcting at least one remaining optical aberration in thelens. The at least one remaining optical aberration may include a highorder aberration.

Another embodiment is a method of making an optical lens. The methodincludes applying a spacer having a predetermined thickness to a firstlens. The method further includes applying a curable material to a firstlens. The method further includes debubbling the curable material toremove trapped gas. The method further includes positioning a portion ofthe curable material onto an off-center location of a second opticalelement and mating the second optical element and the first opticalelement. The mating may be performed so that the curable material formsa layer having a thickness defined by the predetermined thickness of thespacer. The curable material may be at least partially cured to form asemi-cured material. The curable material may be further cured to definea pattern of refractive index wherein the pattern of refractive indexcorrects at least one high order aberration in an optical path throughthe optical lens.

Another embodiment is a method of making an optical lens. The methodincludes dispensing a curable material to form a substantially planarsheet. The method further includes curing the curable material to form asemi-cured material wherein the index of refraction of said semi-curedmaterial can be selectively varied. The method also includes applying atleast a portion of the sheet to a first optical element. The methodfurther includes affixing a second optical element to the first opticalelement and sealing the curable material therebetween. In oneembodiment, the method may further include curing the semi-curedmaterial to define a pattern of refractive index wherein the pattern ofrefractive index corrects at least one high order aberration in anoptical path through the optical lens.

Another embodiment is a method of making a lens blank. The methodincludes mating a first optical element at a predetermined distance froma second optical element so as to form a cavity therebetween. The methodfurther includes filling the cavity with a curable material and at leastpartially curing the curable material to form a semi-cured material.

Yet another embodiment is method of making an optical lens. The methodincludes forming a substantially planar sheet of gel. The method furtherincludes applying at least a portion of the substantially planar sheetof gel to the at least one surface of the mold to form a first layer ofmaterial having a selectively variable index of refraction. The methodfurther includes forming a second layer of material within the mold. Inone embodiment, the method further includes curing the first layer ofmaterial to define a pattern of refractive index. The pattern ofrefractive index may correct at least one high order aberration in anoptical path through the optical lens.

Another embodiment is a method of making an optical lens. The methodincludes forming a first layer of curable material within a mold. Thecurable material includes a mixture of materials having low and highrefractive indices. The method further includes exposing the layer ofcurable material to a first pattern of radiation to define a firstpattern of refractive index in the layer wherein the first pattern ofrefractive index corrects at least one high order optical aberration inan optical path through the optical lens. The method also includesexposing the layer of curable material to a second pattern of radiationto define a second pattern of refractive index in the layer wherein thesecond pattern of refractive index corrects at least one low orderoptical aberration in an optical path through the optical lens.

Another embodiment is a method of making an optical lens. The methodincludes filling a mold with a curable material. A pattern of refractiveindex to correct at least one optical aberration is calculated. Thecurable material is irradiated with a two dimensional grayscale patternso as to form a first layer having defined therein the pattern ofrefractive index. Uncured material is removed from the mold. The mold isfilled with a second layer of curable material. The second layer ofcurable material is cured within the mold.

Yet another embodiment is a method of making an optical lens. The methodincludes depositing a first layer of material on to at least one surfaceof a mold so as to define a pattern of refractive index. The pattern ofrefractive index corrects at least one high order aberration in anoptical path through the optical lens. The method further includesforming a second layer of material within the mold. In one embodiment,depositing the layer of material includes depositing a varying thicknessof the layer of material to define a pattern of varying thickness andwherein the pattern of varying thickness comprises the pattern ofrefractive index. In another embodiment, depositing the first layer ofmaterial comprises depositing a mixture of at least two materialswherein the mixture of the at least two materials is varied to definethe pattern of refractive index.

Another embodiment is a method of making a customized lens. The methodincludes applying a layer of curable polymer to an optical element andselectively curing the layer to vary the thickness of the layer so as todefine a pattern of refraction that corrects at least one opticalaberration. The method may further includes substantially uniformlycuring the layer.

Another embodiment is a method of making a customized lens. The methodincludes applying a layer of curable material to an optical element. Themethod further includes vacuum forming the layer of curable material tothe optical element. The method also includes at least partially curingthe layer of curable material. The method further includes selectivelycuring the layer of curable material to define a pattern of refractionin the layer that corrects at least one high order optical aberration inan optical path through the lens.

Another embodiment is a system for customizing optical correction in anoptical system. The system includes means for measuring opticalaberration data of the optical system, means for determining, based onthe optical aberration data, a lens definition comprising a correctionof at least one high order optical aberration, and means fabricating acorrecting lens based on the lens definition.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flow chart depicting a process for producing a spectaclelens.

FIG. 2 is a flow chart depicting an embodiment of a method ofmanufacturing a lens for correcting optical aberrations as part of theprocess of FIG. 1.

FIG. 3 is a flow chart depicting another embodiment of a method ofmanufacturing a lens blank as a part of a method of making a lens, suchas depicted in FIG. 1.

FIG. 4A illustrates a lens blank at one step of the method depicted inFIG. 3.

FIG. 4B illustrates the lens blank of FIG. 4A at another step of themethod of FIG. 3.

FIG. 4C illustrates the lens blank of FIG. 4A at the completion of themethod of FIG. 3.

FIG. 4D graphically illustrates another embodiment of a method ofmanufacturing a lens, similar to the method depicted in FIG. 3.

FIG. 4E is a diagram illustrating an embodiment of a method, similar tothe embodiment of FIG. 4D, of creating an optical element by dispensinga mixture of low and high refractive indices formulations between thesetwo molds.

FIG. 5 is a flow chart depicting another embodiment of a method ofmaking an optical lens as part of the process of FIG. 1.

FIG. 6 is a flow chart depicting an embodiment of a method of making alens for correcting optical aberration similar to the method depicted inFIG. 1, but using a mold.

FIGS. 7A-7E graphically illustrate steps of making a lens, such as inthe method depicted in FIG. 6.

FIGS. 7F-7J graphically illustrate steps of a method making a lenssimilar to the method depicted in FIGS. 7A to 7E, except that the layerhas a generally uniform thickness and is composed of varying proportionsof materials to vary the index of refraction across the surface of thelens.

FIG. 8 is a flow chart depicting an embodiment of a method of making alens blank using a free standing filmy gel of polymer material similarto the method depicted in FIG. 6.

FIG. 9 is a flow chart depicting an embodiment of a method of making alens blank using a free standing filmy gel of polymer material into alens blank for use in, e.g., an embodiment of the method of FIG. 1.

FIG. 10 is a simplified block diagram depicting one embodiment of asystem for producing spectacle lens, e.g., using one embodiment of themethod of FIG. 1.

FIG. 11 is one embodiment of a method of producing spectacles using anembodiment of a system such as depicted in FIG. 10.

FIG. 12 is one embodiment of a method of producing customized framedlenses.

FIG. 13 graphically illustrates another embodiment of a method ofmanufacturing a lens having a layer with a varying thickness.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

The following detailed description is directed to certain specificembodiments of the invention. However, the invention can be embodied ina multitude of different ways as defined and covered by the claims. Inthis description, reference is made to the drawings wherein like partsare designated with like numerals throughout.

Spectacle lens are typically formed by grinding the lens blank tocorrect the measured optical aberrations and edging a lens blank to fita pair of spectacle frames. This correction is typically limited to loworder aberrations. In addition, the corrections are typically incompletein that grinding is typically performed to a margin of 0.25 D.

By using a device that measures wavefront aberrations in the eye ofpatient, much more precise measurements of a patient's eye can beobtained. The resulting measurements can be used to calculate anoptimized lens definition. In one embodiment, the lens definition candefine a pattern of refractive index that corrects one or more opticalaberrations in an optical path through the lens that, when manifested inan optical lens, such as a spectacle lens, corrects the wavefrontaberrations of the patient more precisely than is typically possible.Patients will thus be able to see at very near the peak of their ownoptical capabilities.

It is to be appreciated that, as used herein, “correction” of opticalaberrations does not necessarily mean that the optical aberrations arecompletely eliminated but, rather, is to be understood to generally meanreducing, minimizing, or optimizing the optical aberrations. Moreover,because in some instances increasing certain high order aberrations hasbeen found to improve vision, “correction” of aberrations can alsoinclude adding or increasing certain optical aberrations. An opticalelement may include a thick or thin lens blank, a plano lens, acorrective lens such as a spectacle lens, a contact lens, an opticalcoating, an intraocular lens, or any other light transmissive componentincluding combinations of other optical elements. A plano opticalelement, i.e., one that does not possess any refractive power, may beflat, or may have a curve for cosmetic reasons, e.g. to have anappearance mimicking a standard spectacle lens.

FIG. 1 is a top level flow chart illustrating a method 100 of makingcustomized lens. Beginning at a step 110, a patient's eye is measured.In one embodiment, the patient's vision parameters, such as low orderand/or high order aberrations are measured using an aberrometer(comprising a wavefront sensor, for example). The aberrations can bemeasured using a wavefront sensor, such as a Shack-Hartmann, diffractiongrating, grating, Hartmann Screen, Fizeau interferometer, ray tracingsystem, Tscherning aberrometer, skiascopic phase difference system,Twymann-Green interferometer, Talbot interferometer, for example.Exemplary aberrometers are described in more detail in U.S. Pat. No.6,721,043 to Platt. B. et. al. in “Light Adjustable AberrationConjugator”, which is hereby incorporated by reference in its entirety.Other embodiments of an aberrometer are disclosed in U.S. patentapplication Ser. No. 10/076,218, entitled “APPARATUS AND METHOD FORDETERMINING OBJECTIVE REFRACTION USING WAVEFRONT SENSING,” filed Feb.13, 2002; and U.S. patent application Ser. No. 10/014,037, entitled“SYSTEM AND METHOD FOR WAVEFRONT MEASUREMENT,” filed Dec. 10, 2001, eachof which is hereby incorporated by reference in its entirety. In oneembodiment, the vision parameters may include data obtained by testingthe patient's vision through a trial, or test, lens that is configuredto correct one or more high or low order optical aberrations.

In addition to measuring aberrations, other vision parameters can beobtained such as the patient's vertex distance, pupil size, pupildistance, frame information, gaze, or x-y tilt. Further details oftaking such measurements are described in U.S. Pat. No. 6,682,195,entitled “CUSTOM EYEGLASS MANUFACTURING METHOD,” issued on Jan. 27,2004, which is hereby incorporated by reference in its entirety.

Moving to step 120, a pattern of refraction in an optical lens iscalculated to correct the measured aberrations. The pattern ofrefraction can be effected in an optical element by, for example,defining a two dimensional pattern of refractive index across the faceof the optical element or by varying the thickness of a layer ofmaterial comprising the optical element to vary the refractive index andthereby define the pattern of refraction. For example, standardspectacle lens typically defines a pattern of refraction by varying thecurvature of the lens material, and thus the thickness of the lensmaterial, over the surfaces of the lens. The curvature of the lens,along with the refractive index of the lens material, defines thepattern of refraction of the standard spectacle lens. Such standardlenses typically correct one or more low order optical aberrations. Inone embodiment, the pattern of refraction is at least partially definedin terms of sphere, cylinder, and axis. In such an embodiment, a furtherpattern of refraction for correcting high order aberrations and residualaberrations resulting from, for example, grinding errors can be furthercalculated for application to the lens. In other embodiments, thepattern of refraction can be calculated in terms of low and high orderZernike polynomials for application to a material that can be processedor cured to alter its refractive index.

In one embodiment, the vision parameters are used by a vision metric tooptimize the lens definition. The lens definition can include thewavemap, a pattern of refraction, a prescription in terms of sphere,cylinder, and axis, or any other relation to a pattern of refraction orcorrection. In addition, the lens definition may include an opticalcenter, multiple optical centers, single correction zones, multiplecorrection zones, transition zone, blend zone, swim region, channel, addzones, vertex distance, segmental height, off-axis gaze zone, logos,invisible markings, etc.

Next at step 130, a lens is manufactured to correct both low and highorder optical aberrations. One embodiment of such a lens is disclosed inmore detail in U.S. patent application Ser. No. 10/218,049, entitled“APPARATUS AND METHOD OF CORRECTING HIGH ORDER ABERRATIONS OF THE HUMANEYE,” filed Aug. 12, 2002, herein incorporated by reference in itsentirety. Embodiments of methods of manufacturing the lens may includenumber of different methods for forming a lens having a calculatedpattern of refractive index, such as are described in more detailherein, including depositing of a layer that is cured to include thecalculated pattern of refraction, grinding or freeform surfacing of alens surface, cast molding and combinations thereof.

FIG. 2 is a flow chart depicting one embodiment of a method 130 ofmanufacturing optical lens blank that can receive a pattern ofrefractive index that is calculated based on the wavefront aberrationsfrom, e.g., a human eye. The method 130 begins at a step 210, where aphotosensitive gel layer is formed between a first and second opticalelement. In one embodiment is a thick and thin lens. Other embodimentscan include two thick lenses or two thin lenses. A thick optical lens isgenerally thicker, can be plano, and generally refers to an opticalelement that can provide corrective power. While either a thick or thinlens can be contoured to change the refractive power of the element, thethicker lens provides a greater range for contouring. Such contouringcan include grinding and polishing, laser ablation, or freeformsurfacing. Desirably, the front optical element, the one on which lightinto the eye is initially incident, is a thin lens that generallyprovides no power. Note that the radius of curvature of the frontoptical element generally defines the refractive power of the opticallens blank. The selection of a thick or thin lens for each opticalelement can be made on the basis of the desired corrective power of thefinal optical blank. For example, if a higher power lens is desired, twothick lenses can be used. If only minimal low order correction isdesired in a particular lens, two thin lenses may be used.

The photosensitive gel layer can be selectively cured to vary its indexof refraction. For example, it can be cured in a pointwise, stepwise, orcontinuous manner to define a two dimensional pattern of refraction thatcorrects one or more optical aberrations in an optical path through thelens. As used herein, a material that can be cured in such a way may bereferred to as having a selectively variable index of refraction. Thepattern of refraction of the layer can be produced so as to define acorrection to one or more optical aberrations. It is to be appreciatedthat while certain embodiments of this and other methods are discussedherein with respect to a photosensitive gel layer, other embodiments canuse a layer of any other material that has a selectively variable indexof refraction, e.g., that can be processed or cured to vary the index ofrefraction.

In one embodiment, the photosensitive gel layer is formed of a polymergel that is first formed in, for example, a large sheet. A co-pendingU.S. patent application Ser. No., entitled “STABILIZED POLYMER MATERIALSAND METHODS,” Attorney Docket No. OPH.031A, entitled “STABILIZED POLYMERMATERIALS AND METHODS,” filed on even date, and incorporated byreference in its entirety, discloses embodiments of the photosensitivegel layer. A preferred embodiment is formed using a compositionincluding a matrix polymer having a monomer mixture dispersed therein,the matrix polymer being selected from the group consisting ofpolyester, polystyrene, polyacrylate, thiol-cured epoxy polymer,thiol-cured isocyanate polymer, and mixtures thereof; the monomermixture comprising a thiol monomer and at least one second monomerselected from the group consisting of ene monomer and yne monomer.

In one embodiment, a sheet of this matrix polymer, or gel, is formed. Aportion of this sheet is placed between two optical elements to form alens blank. A single large sheet can be formed in bulk with portionsdiced and used to form many lens blanks. The two optical elements areaffixed to form a lens blank. The first and second optical elements canbe plano lens or have correction power. In one embodiment, lens blanksare prepared to have a range of corrective power in the first and/orsecond lens, e.g., in a range separated by 0.25 diopter, or 1 diopter.In preferred embodiment, one or both of the optical elements are a thicklens that can contoured, for example, by grinding and polishing, toprovide at least partial correction of one or more low orderaberrations. Next at step 215, in such an embodiment, one or both outersurfaces of the optical elements may be contoured. In anotherembodiment, the lenses can be contoured before affixing the lensestogether to form the lens blank. The lenses can be contoured usingconventional grinding and polishing methods, or by freeform surfacingusing a three axis turning machine such as manufactured by SchneiderOptics, LOH, Gerber, Coburn, or otherwise formed to provide at leastpartial correction of optical aberrations. As used herein freeformsurfacing refers to any method of point-to-point surfacing or machining.

Next at step 220, a pattern of refraction or refractive index, such ascalculated in step 120 of method 100, is formed in the photosensitivegel layer. This pattern is configured to correct optical aberrations ina human eye. In one embodiment, the pattern of refraction formed in thephotosensitive gel is calculated to correct high order aberrations andlow order aberrations that are not otherwise corrected by, for example,the thin lens of a lens blank, or surfacing of the thin lens from a lensblank.

In one embodiment, this pattern of refractive index can be formed usinga source of radiation, e.g., ultraviolet light, having a two dimensionalgrayscale pattern. A two dimensional grayscale pattern of radiationincludes any pattern of radiation that varies in intensity, e.g.,grayscale, in a two dimensional pattern when directed onto a surface,e.g., of an optical element. In one embodiment, radiation is directedthrough a photomask to control the amount of radiation received atdifferent points in the optical element. The photomask can compriseregions that are essentially opaque to the radiation, regions that areessentially transparent to the radiation, and regions that transmit aportion of the radiation. The lens blank is exposed to the radiation fora predetermined time to cure and partially cure the photosensitivepolymer such that the pattern of refractive index is formed in the lensblank. Other embodiments can use digital mask systems such as DigitalLight Projector (DLP) along with a UV light source. The UV light sourcecan include a UV Vertical Cavity Surface Emitting Laser (VSCEL), tripleYAG laser, or a UV-LED.

Moving to step 230, the blank can be edged and mounted to fit a pair offrames for use by the patient. In one embodiment, the step 210 can beperformed en mass to provide an inventory of lens blanks that can beconveniently processed (for example, according to steps 210 and 230) at,in some embodiments, a different location, e.g., an optometrist's officewhere the patient's eye is also measured.

FIG. 3 is a flow chart depicting another embodiment of a method forforming the photosensitive gel layer between a lens blank and a lenscover such as in step 210 of FIG. 2. Beginning at step 310, passages areformed in the lens blank. The lens blanks can be formed of CR-39 orother suitable materials such as polycarbonate, Finalite™ (Sola), MR-8monomer (Mitsui), or any other material known in the art. In oneembodiment, these passages can be drilled or cut into the lens blank.Generally, the lens blank is larger than the final lens that is to befit into a spectacle frame. Thus, the area in which the passages areformed is removed from the final lens and does not inhibit the opticalcorrection of the lens. In another embodiment, the passages are formedalong with the lens blank, e.g., in a mold or press. It is to beappreciated that while two passages are discussed herein, additionalpassages can be formed in the lens blank to, e.g., allow faster or moreeven filling of the cavity between the lens blank and lens cover.

Next at step 320, the lens blank is mated with the lens cover by spacingthe lens cover and lens blank at a predetermined distance determined bya spacer, or gasket. In one embodiment, the spacer is a solid materialplaced between the lens blank and cover. However, any method ofmaintaining the predetermined distance between the blank and cover canbe used. Moving to step 330, a seal is formed around the perimeter ofthe lens blank and lens cover to form a sealed cavity therebetween. Inone embodiment, an adhesive spacer with a thickness in the range of 1 to100 mil is sandwiched between the lens blank and cover lens to form andseal the cavity. In one embodiment, the adhesive spacer is approximately20 mil thick.

In another embodiment, mating the lens blank and lens cover to make acavity therebetween includes a taping method. A cavity is formed byholding two lens blanks apart mechanically, e.g., by clamps or a jig, tocontrol the thickness of the cavity. A tape or similar material isapplied around the edges of the mated lens blank and cover to form asealed cavity by wrapping the deformable elastic tape or a rubber gasketover the edges of two lens blanks and holding them together with aclamp. Further, in one embodiments, rather than forming a passagethrough the lens blank at step 310, the passage is formed through thespacer or tape, e.g., via inserting a syringe or other dispenser throughthe tape or gasket.

Continuing to step 340, a curable material formulation, in oneembodiment, a photosensitive material, made, e.g., of Thiol-Ene, or acomposition as described above, is mixed, degassed and transferred to asyringe in a clean environment. Using a fluid dispenser, such as adispenser from EFD, Inc., or a mechanical-type dispenser, such as asyringe, the mixed formulation is injected through one of the passagesinto the cavity while the passage is for venting of the air from thecavity. In some embodiments, the material may be dispensed through apassage in the spacer or seal. In one embodiment, such a passage may beformed by the syringe used to dispense the curable material. Next atstep 350, the injected lens blank is placed in an oven maintained at anelevated temperature (for example, approximately 75° C.) to cure theinjected material to form the photosensitive film. In anotherembodiment, the curing process can be performed at room temperature,depending upon the curing properties of the injected material.

FIGS. 4A-4C depict side views of a lens 401 at various steps ofmanufacture using an embodiment of the method of FIG. 3. In particular,FIG. 4A depicts a lens 401 following completion of steps 310, 320, and330 of the method of FIG. 3. A lens cover 410 is spaced from a lensblank 412 by adhesive backed spacers 414. The spacers 414 act as agasket surrounding the edge of lens assemblies to form a cavity 416. Twoor more passages 418 are formed in the lens blank 412 to allow materialto be introduced into the cavity 416.

FIG. 4B depicts the lens 401 of FIG. 4A upon completion of the step 340of FIG. 3 in which the photosensitive material has been introduced intothe cavity 416 to form a layer 420. FIG. 4C depicts the lens 401following the step 350 of the method of FIG. 3. Heat or other curingmethod, e.g. UV light, is applied to the layer 420 to form aphotosensitive gel 422.

FIG. 4D graphically illustrates another embodiment of a method ofmanufacturing a lens, similar to the method depicted in FIG. 3 using acast molding approach. As described above, a low or high refractiveindex formulation is dispensed between two optical molds. In oneembodiment, the optical molds may define a shape, e.g., a radius ofcurvature, that forms a selected low order prescription in the lensformed by the mold. Beginning as shown in block 452, the formulationthat has been dispensed between two optical molds is selectivelyirradiated to create low or high order aberration corrected region 453,as shown in block 454. In one embodiment, the formulation in the mold isirradiated with a two-dimensional grayscale pattern of radiation. Thetwo-dimensional grayscale pattern of irradiation can be generated bypassing a approximately uniform light beam through a photomask, a filtersuch as a liquid crystal display screen, or by generating a twodimensional pattern of light such as from a two-dimensional array oflight emitting diodes or a DLP with a UV light source. As shown in block456, the formulation is then replaced with a second high or lowrefractive index formulation. As is next shown in block 458, the entiremold is irradiated a second time to cure the second formulation. In oneembodiment, the second formulation is also irradiated with atwo-dimensional grayscale pattern to cure any remaining low or highorder aberrations. Moving to block 460, the lens is then removed fromthe molds, edged, mounted in a frame, and dispensed to the patient. Inone embodiment, the irradiation shown in blocks 452 and 458 is performedat room or elevated temperatures.

Alternately, the cast molding method may involve controlled depositionof two or more formulations of low and high refractive index on one ofthe optical molds to correct for high order aberrations followed bycorrection for low order aberrations by filling a space between twooptical molds, which may provide radii of curvature to correct a loworder prescription, with a low or high refractive index formulation.Thermal or light induced polymerization at room or elevated temperaturesallows polymerization of the formulation between the molds. The curedoptical element may then be removed from the mold, edged, mounted inframes, and dispensed to the patient.

FIG. 4E is a diagram illustrating an embodiment of a method, similar tothe embodiment of FIG. 4D. As shown in block 470, two formulations aredispensed between two optical molds. The formulations can include amixture of low and high refractive indices formulations. In oneembodiment, the high refractive index formulation comprises acrylatecomponents that undergo fast photopolymerization while the lowrefractive index formulation comprises vinyl or allyl components thatundergo relatively slower photopolymerization as compared to theacrylate components. Alternately, the low refractive index formulationmay comprise fast reacting acrylate components and the high refractiveindex formulation may comprise slow reacting vinyl or allyl components.

As shown in block 470, the formulation in the optical molds can beexposed on one side to spatially modulated high intensity lightradiation to define a cured volume having a refractive index thatcorrects high order aberrations, while the other side of the mold may beconcurrently exposed to spatially modulated low intensity light forcorrecting low order aberrations. The low and high intensity modulatedlight crosslinks the fast and slow reacting formulations at differentspeeds where the fast curing formulation is selectively cured to agreater extent as compared to the slow curing formulation which barelyundergoes any curing. If there is a need to control the extent ofphotopolymerization of one formulation over the other, step-growthphotopolymerization of thiol and ene components (low or high refractiveindex) may be incorporated. One embodiment uses the method offrontal-polymerization, where the polymerization front is easilymonitored, to control the depth of photopolymerization of one of the twoformulations. Also, based on the amount of photoinitiator,photoinitiator-additive (UV-absorber or inhibitor) present in theformulation, the depth of curing can be controlled. The curing front canbe controlled to create a contour surface corresponding to thecorrection of low or high order aberration needed in this formulation.Block 472 illustrates the resulting cured contoured volume in the lens.The uncured material can be removed from the mold and replaced with asecond layer of curable material. This second material can be furthercured to produce the lens, which can then be removed from the mold asillustrated in block 474.

In order to overcome any physical phase separation between the two curedformulations, one of the components in the formulation may be selectedto be the same. Additionally, the lenses can be engraved with fiduciarymarks to locate the segmental height, addition zones, etc. As shown inblock 474, the fully corrected lenses can be removed from the opticalmold and after the edging process, these lenses can be mounted in theframe and dispensed right at the optics lab. The above-described processof cast molding advantageously corrects aberration zones in thecustomized lens with precision and accuracy as they are controlledduring the cast molding process. Additionally, the contour surfacecorresponding to the low and the high order aberration corrections maybe precisely controlled in the lens. The low and high intensitymodulated light can be directed into the lens from either side. Blocks480, 482, and 484 illustrate another embodiment of the method shown inblocks 470, 472, 474. In embodiment shown in block 480, the orientationof the low and high intensity radiation is reversed with respect to theembodiment illustrated in block 470.

FIG. 5 depicts one embodiment of a method 500 of performing the step 210of FIG. 2. Beginning at step 510, spacer materials are prepared forplacement between a thick and thin lens blank. Beginning at step 510, apair of optical elements, e.g., lens blanks are cleaned. Each of thelens blanks can be formed of a material such as CR-39, polycarbonate,Finalite™ (Sola), MR-8 monomer (Mitsui), 1.67, 1.71, 1.74 materials, orany other suitable material as would be apparent to one of skill in theart. In one embodiment, the optical elements include a thick and thinlens blank. In other embodiments, two thick or two thin lens blanks maybe used, depending upon the corrective power of the lens to be produced.Because any contaminants formed into an optical lens can causeaberrations, the materials used in the process should be kept veryclean. A gas such as argon, nitrogen, or air, preferably filtered, canbe blown over the optical elements to remove contaminants. Next at step512, spacer materials are applied to the thin lens. In one embodiment,the spacer materials include 2 layers of 10 mil ceramic tape for a 20mil gap, which are cut into small rectangles. Others embodiment can useother thicknesses of tape or other types of gasket, including adhesivegasket materials.

Moving to step 520, the lens filler material is mixed. The material caninclude any suitable photosensitive material described herein.Continuing at step 522, an amount of the filler material having apredetermined mass is measured and applied to the thin lens.

In addition to other contaminants, air bubbles in the filler materialcan also cause optical aberrations in the final lens. Thus, next at step524, the thin lens is placed in a vacuum chamber to remove air bubblesfrom the filler material. Moving to step 526, the vacuum chamber isdepressurized using, e.g., argon gas. Moving to step 530, the fillermaterial is inspected for any remaining air bubbles. In one embodiment,these can be removed by carefully tooling the material by hand to movethe pocket to the surface where it can be collapsed.

Placing the thick lens blank over the thin lens blank can tend tointroduce air pockets into the final lens. However, it has been foundthat by placing a droplet of the filler material onto the thick lens,this tendency is substantially reduced. Thus, moving to step 532, adroplet of the filler material is placed slightly off center on thethick lens. Next at step 534, the filler material on the thick lens isslowly compressed onto the main mass of filler material on the thin lensuntil the final lens is formed. Continuing to step 536, the lens iscured, e.g. using heat, to form the filler material into aphotosensitive gel. The method 500 then ends, having formed a lens blankwith a photosensitive gel layer such as is used in the method of FIG. 2.

FIG. 6 depicts one embodiment of a method 600 of forming a lensconfigured to have a pattern of refractive index calculated to correcthigh and low order optical aberrations. Beginning at a step 610, a basesurface of a mold is coated with a scratch resistant coating. Next atstep 612, a layer of polymer is deposited on the mold surface to definea predetermined index of refraction. Other embodiments of programmingthe lens are described below with respect to FIGS. 7A-7E and FIGS. 7F-J.

Continuing to step 614, a mating member of the mold is positioned at apredetermined distance from the base of the mold to define a cavity. Theshape of this cavity can be calculated to correct one or more low orderaberrations. Next at step 616, the cavity is filled with a suitablepolymer or polymerizable material, such as CR-39, polycarbonate,Finalite™ (Sola), MR-8 monomer (Mitsui), 1.67, 1.71, 1.74 materials, orany other suitable material known in the art, which forms asubstantially rigid lens body. Moving to step 618, the polymer materialis cured. The lens can then be removed from the mold and fitted tospectacle frames.

FIGS. 7A to 7E depicts a simplified diagram of a mold during variousacts of one embodiment of the method 600. FIG. 7A depicts a mold base710 being centered with a known center line along line 702. Note thatthe layers depicted in FIGS. 7A to 7E are not necessarily to scale.

FIG. 7B depicts one embodiment of step 612 of the method 600. A head 712deposits a spray 714 of droplets to form a polymer layer 716. Thethickness of the polymer layer 716 at a location on the layer determinesthe refractive index of the layer at that location. The head 712deposits the layer to have a thickness that is varied so as to define apredetermined pattern of refraction. Stated differently, the surfaceprofile or peak to valley height difference of the deposited polymercorresponds to the desired aberration correction.

FIG. 7C depicts a mating member 720 placed over the base 710 to form acavity as described with respect to step 614 of the method 600. A secondlayer of material can be formed within a mold to maintain an opticalquality and uniformity of the surface. FIG. 7D depicts the mold afterhaving been filled with the polymer, as described with respect to thestep 616 of the method 600. FIG. 7E depicts a completed optical lens 724after having been removed from the mold. This optical lens can be fittedto a pair of spectacle frames.

FIGS. 7F-7J illustrate steps of a method making a lens similar to themethod depicted in FIGS. 7A to 7E, except that the layer has a generallyuniform thickness and is composed of varying proportions of materials tovary the index of refraction across the surface of the lens. In anotherembodiment, programming of lenses, e.g., defining the pattern ofrefraction, is performed by controlled deposition of two or morecompatible formulations of varied refractive indices onto lenses 710that have already been corrected for lower order aberrations. Theformulations are photopolymerized during or after depositions to fix thecorrected low order and high order aberrations. An exemplary process ofprogramming of lenses by deposition includes the following steps:

(a) as depicted in FIG. 7G, positioning a first spray head and a secondspray head 716 at an operative distance from a substrate 710;

(b) projecting a first droplet from the first spray head onto apre-selected location on the substrate to form a first depositeddroplet, the first droplet comprising a first amount of a first polymercomposition;

(c) projecting a second droplet from the second spray head onto thesubstrate in close proximity to the first deposited droplet, the seconddroplet comprising a second amount of a second polymer composition;

(d) forming a first polymer pixel on the substrate, the first polymerpixel comprising the first polymer composition and the second polymercomposition in a first ratio;

(e) adjusting at least one of the first and second spray heads to allowan additional droplet to be projected, the additional droplet beingdifferent from at least one of the first and second droplets;

(f) adjusting the positioning of the first and second spray heads withrespect to the substrate; and

(g) repeating steps (a)-(f) to thereby form a second polymer pixeladjoining the first polymer pixel, the second polymer pixel comprisingthe first polymer composition and the second polymer composition in asecond ratio so as to form the layer. The pixels together form the layer716 of FIG. 7G. This process is further described in U.S. patentapplication Ser. No. 10/253,956 by Lai, et al., filed on Sep. 24, 2002,and titled “Optical Elements And Method Of Making Them”, which is herebyincorporated by reference in its entirety. As with the method describedwith respect to FIGS. 7A-7E, a second layer of material can be formedwithin a mold to maintain an optical quality and uniformity of thesurface.

FIG. 8 is a flow chart depicting one embodiment of a method 800 ofproducing an optical lens blank using a mold process similar to that ofthe method 600 discussed with respect to FIG. 6. Beginning at step 810,a scratch resistant coating is applied to the mold base 710. Next atstep 812, a layer of photosensitive gel is formed. In one embodiment, asheet of photosensitive polymer gel, as described with respect to step210, above, can be formed in bulk to provide a gel layer for manylenses. Moving to step 814, a portion of the sheet is placed over themold base 710.

Continuing at step 816, the mating member 720 of the mold is placed overthe mold base 710 to form a cavity between the mating member 720 and thepolymer gel layer (not shown in FIG. 7C, but comprising a layersimilarly placed to the layer 716). Next at step 820, the cavity isfilled with volume 722 of a polymer, such as CR-39, that forms thesupporting body of the lens. Next at step 822, the polymer volume 722 iscured to produce an optical lens blank. The lens blank can have apredetermined pattern of refraction formed in the gel layer by, forexample, the masking method described above. The gel layer can also befurther bulk cured to increase the rigidity of the layer to preventdamage from physical contact. The cured gel may be coated with a scratchresistant or hard coating to enhance its mechanical strength.

In another similar embodiment, the portion of the sheet can be vacuumformed with a stock optical element to form a lens. The stock opticalelement can be a formed of a polymer such as CR-39 or a similarmaterial, such as those known in the art. The stock optical element maybe plano or provide a correction of one or more low order opticalaberrations. In one embodiment, the portion of sheet of semi-curedmaterial is applied to the stock optical element with a small amount ofmonomer, such as used in to form the sheet, between the stock opticalelement and the portion of the sheet. The lamination of the portion ofthe sheet and the optical element can be placed into a flexible mold.Vacuum pressure is applied to pull the stock optical element into theportion of the sheet and against the flexible mold. The monomer can becured through application of light or heat while the vacuum is applied.In another embodiment, monomer material is introduced between the stockoptical element and the mold. The vacuum is applied to force the monomerinto a thin layer over the surface of the stock optical element betweenthe element and the flexible mold. The monomer is at least partiallycured to form the semi-cured layer of material. The resulting lens blankmay be edged and applied or mounted to a frame. The lens blank can befurther cured to define a pattern of refraction in the material thatcorrects one or more high order optical aberrations. More details of onesuch process are disclosed in U.S. Pat. No. 6,319,433, which isincorporated by reference in its entirety.

In another embodiment, a mounted or framed lens may be used in place ofthe stock optical element. A layer of semi-cured material is thus formedon a previously prepared, or framed, lens. This layer can be furtherselectively cured to define a pattern of refraction that corrects one ormore high order aberrations. In addition, one or more low orderaberrations may also be corrected in the lens. For example, small loworder corrections that are not corrected by stock lens, e.g., less than0.25 diopters, may be corrected in the layer. In addition, high ordercorrections may be added to existing framed lens as provided by apatient. For example, an existing or previously obtained optical lensmay be modified to correct any remaining low or high order aberrationsthat are not corrected by the unmodified lens.

FIG. 9 is a flow chart of an embodiment of another method 900 ofmanufacturing a lens blank. Beginning at step 910, a sheet, or layer ofa photosensitive gel is formed, as is discussed above. Next at step 912,the sheet is diced to form a group of freestanding optical flats.

Moving to step 914, a pattern of refraction calculated to correctoptical aberrations can be formed within the gel by photo-curing, forexample, using the masking method discussed herein. In one embodiment,the optical flat can be stamped or otherwise formed into a curved lensshape or shaped to correct at least some low order optical aberrations.Moreover, the gel can be further bulk cured to increase its rigidity.

Next at step 916, the method 900 completes by applying one or morecoatings to the optical flat. These coatings can include coatings ofscratch resistant material. In other embodiments, these coatings caninclude materials to provide additional rigidity to the lens. Thecompleted lens blank can be used as described herein to form a completeoptical lens for correcting low and/or high order optical aberrations.

Each of the methods described above can advantageously be performed at asingle or multiple location. More particularly, the process ofrefracting the patient, grinding the semifinished lens blanks,correcting the low and/or high order aberrations, and fitting the framesholding the lenses to the patient's line of sight can be performed atone or multiple location. Thus, a vision prescription can beadministered and customized lenses dispensed to the patient in a singlevisit to an optometrist. Additionally, the purchase of the lens and/orpayment for the examination can be completed at the same location, andduring the same visit, by allowing the patient to pay with a cash, otherlegal tender, or credit transaction.

In yet another embodiment, the patient's low order and/or high orderaberration measured by the aberrometer can be corrected in plano lensespre-mounted in frames. In one embodiment, the plano lenses can be flat,or can have a curve for cosmetic reasons, e.g. to have an appearancemimicking a standard lens. The plano lenses can be made either of arefractive index changing material or of a carrier material suitable forcontrolled deposition. The entire method 100 of measuring the patient'srefraction, selection of framed plano lenses, corrections of low and/orhigh order aberrations, dispensing customized lenses can all beperformed at one location. The correction of low and/or high orderaberration can involve any of the programming methods described above,such as selective refractive index changes that corresponds to thedesired corrections, controlled deposition of low and high refractiveindex formulation that corresponds to the desired corrections, orselective volume change of a layer which varies the height, andthickness of the layer to correspond to the desired corrections.Additionally, cash, other legal tender such as electronic transfers orcredit transactions can be included in the processes involves in makingcustomized lenses.

FIG. 10 is a block diagram illustrating components of an exemplarysystem 1000 for measuring eyes, calculating correction data, andfabricating lenses that correct for the measured disorders. Each ofthese functions can be performed by a component system, e.g., an eyemeasurement system 1010, a correction calculation system 1020, afabrication system 1030, and a billing and payment system 1040. Variousembodiments of the system 1000 can include various embodiments of thesecomponent systems. In some embodiments, some of the component systems1010, 1020, 1030, and 1040 of the system 1000 can be combined to form anintegrated system. For example, in one embodiment, the measurementsystem 1010 can be integrated with the correction calculation system1020. In another embodiment, the measurement system 1010 can beintegrated with the fabrication system 1030. In one embodiment, each ofthe components can be co-located. In other embodiments, the systemcomponents 1010, 1020, 1030, and 1040 can be at separate locations. Themeasurement system 1010 may desirably be located at the office of anoptometrist or other consumer accessible office or storefront. Thefabrication system 1030 may desirably be located at an optical lab. Inone embodiment, the calculating system 1020 is integrated with themeasurement system 1010. In another embodiment, discussed below infurther detail, the calculation system 1020 is located at a centrallocation separated by a computer network or other data communicationssystem to serve one or more measurement systems 1010.

An embodiment of the eye measurement system 1010, can include any one ofthe various wavefront sensors described above to measure visionparameters, such as disorders, or aberrations, of a patient's eye(s).The eye measurement system 1010 can also include a phoropter,autorefractor, or trial lens. Embodiments of the eye measurement system1010 can produce eye measurement data that represents optical low and/orhigh order aberrations.

The correction calculation system 1020 receives the eye measurement dataand determines a lens definition that is used in fabricating lenses.Embodiments of the correction calculation system 1020 can includecomputer hardware, software, firmware, or a combination thereof.

In one embodiment, the correction calculation system 1020 generates awavemap, indicating corrections to compensate for the high and/or loworder aberrations of a patient's eyes. The lens definition can includethe wavemap, a pattern of refraction, a prescription in terms of sphere,cylinder, and axis, or any other relation to a pattern of refraction orcorrection. In addition, the lens definition may include an opticalcenter, multiple optical centers, single correction zones, multiplecorrection zones, transition zone, blend zone, swim region, channel, addzones, vertex distance, segmental height, off-axis gaze zone, logos,invisible markings, etc.

In one embodiment, the lens definition includes one or more numbers orsymbols that identify a pattern of refraction or correction. Suchidentifiers may act as easily transmitted “prescriptions” that can betransmitted electronically, or physically, e.g. via a barcode.

In one embodiment, the correction calculation system 1020 converts thewavefront map into another format indicative of a lens that is optimizedfor the patient. The wavefront map, or other data indicative of a lensoptimized for the patient, can be partly based on characteristics, suchas the patient's vertex distance, pupil size, pupil distance, frameinformation, gaze, segmental height, pantascopic tilt, or x-y tilt, forexample.

To calculate the lens definition, the correction calculation system 1020can generate a conjugate of the optical aberrations of the patient'seyes. In other embodiments, the calculation of the lens definition canbe made with reference to additional metrics for calculating the lensdefinition based on measurements of the patient's eye, includingmeasured optical aberrations. For example, U.S. Pat. No. 6,511,180,issued on Jan. 28, 2003, and incorporated by reference in its entirety,discloses an image quality metric for determining the correction basedon the measured optical aberrations. Other embodiments may use othermetrics to calculate the lens definition. The metric may optimize thelens definition by selecting for correction those optical aberrationsthat are associated with improved subjective measures of a patient'svision. In another embodiment, the metric may include a software neuralnetwork that has been trained using data from test subjects to selectwhich optical aberrations are desirable to correct, add, or leaveuncorrected. More details of such an embodiment are described in U.S.Provisional Patent Application No. 60/546,378, filed on Feb. 20, 2004,incorporated by reference in its entirety.

In one embodiment, the correction calculation system 1020 can alsocalculate the wavefront map based on a color preference. High ordercorrections may vary based on the color of the light passing through thecorrective element. The color preference generally refers to awavelength for which the patient prefers to optimize high ordercorrection. For example, this allows the user to optimize the correctionat wavelengths that are most useful for a specific activity, e.g., greenfor golfing. In one embodiment, the color preference depends on theaberrometer measurement at 850 nm and converting to 550 nm (green), or400 to 800 nm conversion for other color enhancements.

In one embodiment, the correction calculation system 1020 can alsocalculate the lens definition with reference to one or more otherpatient preferences. The patient preferences can include a spectraltint, or color, in the lens. The patient preferences can also includewhether to include a photochromic, light sensitive color change, featureto the lens definition. In addition, the correction calculation system1020 can also calculate the lens definition with respect to otherfeatures such as a ultra-violet coating preference, anti-reflectivecoating preference. In one embodiment, the lens definition can also becalculated with respect to patient wear preference such as how thepatient prefers wear the a high order correction zone in relation to thepatient's frames and view.

The correction calculation system can calculate the lens definition toinclude one or more correction zones. The calculation can includecalculation of the number and size of the correction zones. Each of thecorrection zones can correct for high order aberrations, low orderaberrations, both high and low order aberrations, and front and backradius of curvature. The correction zones can include an optical centerzone or multiple optical centers, e.g., progressive or multi-focal lens.One embodiment of the correction calculation system 1020 can calculate ablending or transition zone between one or more of the correction zonesand other portions of the lens. The transition zone allows the eye'sgaze to smoothly transition from the correction zone, which is generallyonly a portion of the lens, and other portions of the lens. Transitionzones can also include transitions between correction zones. Transitionzones are discussed in more detail in U.S. Pat. No. 6,712,466, entitled“EYEGLASS MANUFACTURING METHOD USING VARIABLE INDEX LAYER,” issued onMar. 30, 2004, and herein incorporated by reference in its entirety.

In one embodiment, the correction calculation system 1020 includes aserver computer that executes software to perform the functions of thecorrection calculation system 1020. The server can communicate withother components of the system 1000 via a network. The network can be alocal or wide area network using any data communications technology,such as would be apparent to one of skill in the art. In one embodiment,the network includes the Internet. In one embodiment, the correctioncalculation system 1020 is co-located with other components of thesystem 1000. In other embodiments, the correction calculation system1020 can be connected to the other components of the system 1000 by thenetwork but located in a different location from the other components ofthe system 1000. In one exemplary embodiment, the correction calculationsystem 1020 is configured to support one or more systems 1000. In suchan embodiment, the correction calculation system 1020 can include abilling module. The billing module can charge based on usage of thecorrection calculation system 1020, e.g., each time that a lensdefinition is calculated or downloaded.

The fabrication system 1030 uses the correction data from the correctioncalculation system 1020 and fabricates customized lenses for thepatient. The fabrication system 1030 can include a programmer thattransfers the lens definition to a lens. The programmer can include aradiation source and photomask as described herein. The programmer canalso include a deposition device configured to perform controlleddeposition of one or more materials.

In one embodiment, the fabrication system 1030 corrects for low orderand high order aberrations concurrently. For example, a lens blank isprogrammed, e.g., using the radiation source and photomask to curephotosensitive material to vary its index of refraction, to correct bothlow and high order aberrations.

In another embodiment, the fabrication system 1030 corrects forsubstantially all of low order aberrations and then for high orderaberrations. In such an embodiment, a blank is selected in which all, orsubstantially all of the low order aberrations have been corrected informing or grinding a shape to the lens blank. The high orderaberrations, and in one embodiment, any remaining low order aberrations,are corrected using, e.g., a programmer. A programmer refers to anydevice for performing one or more of the methods disclosed herein ofdefining a pattern of refraction in an optical element.

In another embodiment, the fabrication system 1030 corrects for highorder aberrations and then for low order aberrations. For example, anembodiment of the method 600 can be used to deposit a layer having apredetermined index of refraction to correct high order aberrationsafter which a mold is used to form a complete lens having a molded shapethat is calculated to correct low order aberrations.

In another embodiment, the fabrication system 1030 corrects for highorder aberrations and then for low order aberrations. For example, asdescribed herein, an embodiment of the method 600 can be used to deposita layer having a predetermined variation in thickness to correct highorder aberrations after which a mold is used to form a complete lenshaving a molded shape that is calculated to correct low orderaberrations.

The fabrication system tracks the correction of the low orderaberrations, programming of at least one high or residual low or highorder aberrations. Fabrication system tracks the right and left lens andthe correction required in each of these lenses. Fabrication systemtracks the lens number, low order ground, polishing, programming,edging, coatings, frames, etc.

A payment system 1040 includes hardware and/or software that allowpatients to pay for lenses, examination fees, and/or other fees withcash, credit, or any other form of payment. Embodiments of the paymentsystem 1040 can be computer hardware, software, firmware, or acombination thereof. Such embodiments can include cash registers, smartcard readers, or charge or credit card readers.

In one embodiment, the eye measurement system 1010 and each of thecomponent systems 1020, 1030, and 1040 are located at a single location.A single location refers to a location such as an office, a storefront,or an optical laboratory. Accordingly, a patient can obtain aprescription and have customized lenses fabricated at a single locationand in a single visit to the location. In another embodiment, thecomponent systems 1010, 1020, and 1030 can be located at one, two,three, or more locations. Each component of the system 1000 cancommunicate using any medium and protocol know in the art. For example,in one embodiment the components of the system 100 can communicate byusing a network, such as an intranet or the Internet. In otherembodiments, the components can provide, e.g., print, data in a tangibleform. For example, the correction calculation system 1020 can print abar code that describes a lens or identifies a lens definition. In otherembodiments, the components can send and receive data via removablecomputer disk, smart cards, or other physical electronic media. Suchprinted and electronic media can be exchanged by physical delivery orfacsimile transmission. Placing each element at separate locationsallows each system to be of optimal size and for expensive equipment,e.g., the calculation system or fabrication system, to be shared betweenmeasurement system locations, e.g., sales locations such as storefronts.

FIG. 11 is one embodiment of a method 1100 of producing spectacles usingan embodiment of the system 1000 such as depicted in FIG. 10. The method1100 begins at step 1110 where the patient's eyes are measured, forexample, by the measurement system 1010. Next at step 1120, a patientselects a frame style. This frame style selection is received, e.g., bythe correction calculation system 1020 and the fabrication system 1030.Moving to step 1130, a spectacle frame, including lenses is selectedfrom a stock of available frames based on the eye measurements and theframe style selection. The lenses of the frame stock include aprogrammable element, e.g., a layer of polymer having an index ofrefraction that can be selectively varied by further, e.g., pointwise,curing. The lens can also have a coating, for example, anti-reflective,scratch resistant, or tint. In one embodiment, the calculation system1020 selects a frame that includes lenses having predetermined opticalcorrections, which may be selected based on the eye measurements. Inanother embodiment, the frames have plano lenses. The correction system1020 may perform this selection based on inventory data. In oneembodiment, the fabrication system 1030 maintains the inventory data andcommunicates it to the correction system 1020. Moving to step 1140, acorrection is calculated based on the eye measurements. In oneembodiment, the correction is also corrected based on the received frameselection. In one embodiment, the correction calculation system 1020performs the calculation. The calculation may be performed with respectto the residual correction required in conjunction with thepredetermined correction of the lenses of the selected frames. In oneembodiment, the frames may be measured so that the correction caninclude a correction for residual errors introduced by the selectedframes. The calculated correction may include corrections to low order,residual low order aberrations, high order aberrations, or any othertype of correction disclosed herein. Next at step 1150, the calculatedcorrection is applied to the lenses of the selected frames using aprogrammer such as those disclosed herein. For example, in oneembodiment, a UV source selectively cures the thin layer of curablematerial to define a pattern of refraction corresponding to thecalculated correction. The frames may then be dispensed to the patientand payment received.

FIG. 12 is one embodiment of a method 1200 of producing customizedframed lenses. Beginning at step 1210, a patient's vision parameters aremeasured, e.g., using the measurement system 1010. In other exemplaryembodiments, the vision parameters are received via one or more of acomputer network, a printed prescription, or a bar code associated withthe vision parameters. Next at step 1220, framed lenses, such asspectacle frames having a pair of mounted lenses, are obtained. Themounted lenses may be obtained from a patient, or a stock of mountedlenses. In one embodiment, the patient provides the framed lens, e.g.,an existing pair of eyeglasses. In one embodiment, the patient's visionis measured through the framed spectacles in step 1210. Moving to step1230, a correction is calculated, for example, by the calculation system1020, based on the vision parameters. In one embodiment, the correctioncan also be based on the framed lens. Proceeding to step 1240, thefabrication system 1030 programs the lens using the calculatedcorrection. In one embodiment, a layer of material defining a surfacecontour is applied to the surface of the framed lenses to define apattern of refraction on one or both lenses corresponding to thecalculated correction. The calculated correction can include acorrection to a low order aberration, a residual low order aberration, ahigh order aberration, a residual high order aberration, or combinationof both. This embodiment is similar to that described in connection withFIG. 7B, except that the layer is applied to the framed lenses ratherthan to a mold. In another embodiment, a layer of material having avarying mixture of materials is applied to the framed lens to define apattern of refraction corresponding to the calculated correction. Thisembodiment is similar to that described in connection with FIG. 7G,except that the layer is applied to the framed lenses rather than to amold. Another embodiment may include applying a layer of photosensitivegel and programming a correction as described with reference to FIG. 9.

Another embodiment includes an optical element that provides acorrection, or introduces, one or more high order aberrations. Certainembodiments may correct or introduce incremental values of one or morehigh order aberrations. Desirably such aberrations may include sphericalaberration, trefoil, or coma. In one embodiment, the optical element isconfigured for use in a phoropter. An optician or other user may placethe optical element in the optical path of a patient. The patient canthen make a subjective determination as to whether the correctionimproves their vision. In another embodiment, the optical elementcomprises a framed spectacles lens. Such framed high order correctivelens may be stocked with the optical elements correcting one or morehigh order aberrations at various powers. A patient may select a frameand correction from a stock of frames, such as with reading glasses.Thus, a patient may easily obtain such lens for, e.g., use in a specificsetting or task.

Another embodiment may include applying a layer of material that iscured such that a differential volume change during curing defines apattern of refraction corresponding to the calculated correction. Onesuch embodiment is described with reference to FIG. 13.

When appropriately cured, e.g., using high intensity light, polymersshrink, are substantially reduced in volume, in a predictable way. Ithas been found that a layer of such high volume material can beselectively cured so that the resulting layer exhibits a pattern ofrefraction that corrects both high and low order optical aberrations.FIG. 13 graphically illustrates another embodiment of a method 1300 ofmanufacturing a lens having a layer with a varying thickness. Beginningat block 1310, a lens assembly is made with an optical element 1302 anda high volume shrinkage monomer layer 1304. In one embodiment, theoptical element 1302 having the high volume change monomer layer 1304can be in a framed or mounted lens. In one embodiment, the opticalelement 1302 can be contoured, e.g., through grinding and polishing, tocorrect, e.g., low order aberrations. In another embodiment, the volumechange of the monomer layer 1304 can correct a low order aberration.Next, as depicted in block 1320, the layer 1304 is exposed to atwo-dimensional grayscale pattern of high intensity radiation. Theradiation pattern can be generated using, for example, a light sourceand a photomask. This pattern of high intensity radiation causesvariable shrinkage of the layer 1304 so as to vary the index ofrefraction across the layer 1304. The monomer composition may includematerials such as those disclosed herein. Further, selection ofappropriate compositions for the layer 1304 and the appropriatewavelength, duration, and intensity of radiation can include selectionsthat are known in the art. The two dimensional grayscale pattern can beselected so as to form a layer 1304 that corrects one or more high orderor low order aberrations. Moreover, the pattern of radiation can befurther calculated to incorporate other features such as are describedherein, including optical center, multiple optical centers, singlecorrection zones, multiple correction zones, transition zone, blendzone, swim region, channel, add zones, vertex distance, segmentalheight, logos, invisible markings. Moving to block 1330, the layer 1304may be exposed to approximately uniform low intensity radiation. Theintensity, wavelength, and duration of this radiation can also beselected as is known in the art to complete curing of the polymer. Thechange in volume can also correct low order aberrations. Block 1340depicts a cured lens. The cured lens may be further treated with opticalcoatings such as hard coatings, UV blocking coatings, anti-reflection,and scratch resistant coatings.

It is also to be appreciated that depending on the embodiment, the actsor events of any methods described herein can be performed in anysequence, can be added, merged, or left out all together (e.g., not allacts or events are necessary for the practice of the method), unlessspecifically and clearly stated otherwise. In addition, the methodsdescribed above can be used for making spherical, aspheric, singlevision, bifocals, multifocal, progressive addition lens, atoric,intraocular lens, or other specialized lenses.

It will be understood that while certain embodiments are describedherein with respect to providing customized vision in eyeglasses, otherembodiments can include provide customized optical correction in otheroptical systems such as optical instruments. For example, opticalinstruments such a camera, telescope, binoculars, or microscope, mayinclude a customized optical element. The customized optical element maybe included as part of a configurable eyepiece, as an element in theinstrument, or in addition to the eyepiece. The customized opticalelement may be configured to correct an optical path in the instrumentincluding a viewfinder or sighting path, and the primary optical path ofa camera, telescope, binoculars, microscope, or similar optical device.The customized optical element is configured to provide customizedcorrection of the optical system such as described herein. In oneembodiment, the customized optical element is configured to implement alens definition including one or more optical aberrations and othervision parameters of at least one eye of a user. In another embodiment,the customized optical element is configured to correct one or moreoptical aberrations in the optical instrument. In yet anotherembodiment, the customized optical element is configured to both correctoptical aberrations of the optical instrument and to include a lensdefinition for at least one eye of a user. In one embodiment, a layer ofmaterial, such as described above, is applied to a lens such as in aneyepiece and cured (if needed) to define a correction such as the lensdefinition on the lens. In one embodiment, the customized element isconfigured to include a customized lens definition for use with one eyeof a user. In another embodiment, binoculars can be customized for eachof the eyes of a user.

While the above detailed description has shown, described, and pointedout novel features of the invention as applied to various embodiments,it will be understood that various omissions, substitutions, and changesin the form and details of the device or process illustrated can be madeby those skilled in the art without departing from the spirit of theinvention. As will be recognized, the present invention can be embodiedwithin a form that does not provide all of the features and benefits setforth herein, as some features can be used or practiced separately fromothers. The scope of the invention is indicated by the appended claimsrather than by the foregoing description. All changes which come withinthe meaning and range of equivalency of the claims are to be embracedwithin their scope.

1-43. (canceled)
 44. A method of making an optical lens comprising:applying a spacer having a predetermined thickness to a first opticalelement; applying a curable material to the first optical element;debubbling the curable material; positioning a portion of the curablematerial onto an off-center location of a second optical element; matingthe second optical element and the first optical element such that thecurable material forms a layer having a thickness defined by thepredetermined thickness of the spacer; and curing the curable materialto form a semi-cured material wherein the index of refraction of saidsemi-cured material can be selectively varied according to a lensdefinition.
 45. The method of claim 44, wherein debubbling the fillermaterial comprises placing the filler material into a vacuum chamber.46. The method of claim 44, wherein at least one of the first and secondoptical elements comprises a thick optical element.
 47. The method ofclaim 44, wherein at least one of the first and second optical elementscomprises a thin optical element.
 48. The method of claim 44, wherein atleast one of the first and second optical elements comprises a lens.49-66. (canceled)
 67. The method of claim 44, wherein the act of matingfurther comprises applying a tape around the circumference of the firstand second optical element so as to seal the cavity. 68-83. (canceled)84. The method of claim 44, wherein applying a curable material furthercomprises: forming a substantially planar sheet of the curable material;and applying at least a portion of the substantially planar sheet of thecurable material to the first optical element to form a layer ofmaterial having a selectively variable index of refraction according tothe lens definition. 85-87. (canceled)
 88. The method of claim 84,further comprising applying an optical coating to the first opticalelement.
 89. The method of claim 84, wherein the optical coatingcomprises a layer of scratch-resistant material. 90-102. (canceled) 103.The method of claim 44, wherein: applying a curable material furthercomprises filling a mold with a curable material, and wherein curing thecurable material further comprises: determining a pattern of refractiveindex to correct at least one optical aberration; irradiating thecurable material with a two dimensional grayscale pattern so as to forma first layer defined therein the pattern of refractive index accordingto the lens definition; removing uncured material from the mold; fillingthe mold with a second layer of curable material; and curing the secondlayer of curable material within the mold. 104-111. (canceled)
 112. Themethod of claim 44 wherein curing the curable material further comprisesselectively curing the layer to vary the thickness of the layer of thecurable material so as to define a pattern of refraction that correctsat least one optical aberration. 113-117. (canceled)
 118. The method ofclaim 112, wherein the selective curing is performed by low or highintensity radiation. 119-120. (canceled)
 121. The method of claim 112,wherein applying a layer of curable material comprises vacuum formingthe layer of curable material.
 122. (canceled)
 123. The method of claim44 wherein applying a curable material further comprises vacuum formingthe layer of curable material to the optical element, and wherein curingthe curable material further comprises selectively curing the layer ofcurable material to define a pattern of refraction in the layer thatcorrects at least one high order optical aberration in an optical paththrough the lens. 124-131. (canceled)
 132. The method of claim 44,wherein the making of an optical lens comprises fabricating an opticallens configured for use in an optical path of at least one of a camera,a telescope, binoculars, or a microscope.
 133. The method of claim 44,wherein the lens definition comprises determining at least one of a loworder aberration, a high order aberration, a high order correction zone,a transition zone, a swim zone, a channel, or a blend zone, and whereinthe lens definition is based at least in part on at least one of apatient's vertex distance, pupil size, gaze, or x-y tilt.
 134. Themethod of claim 84, wherein the lens definition comprises determining atleast one of a low order aberration, a high order aberration, a highorder correction zone, a transition zone, a swim zone, a channel, or ablend zone, and wherein the lens definition is based at least in part onat least one of a patient's vertex distance, pupil size, gaze, or x-ytilt.
 135. The method of claim 103, wherein the lens definitioncomprises determining at least one of a low order aberration, a highorder aberration, a high order correction zone, a transition zone, aswim zone, a channel, or a blend zone, and wherein the lens definitionis based at least in part on at least one of a patient's vertexdistance, pupil size, gaze, or x-y tilt.
 136. The method of claim 47,wherein the method of making an optical lens further comprises freeformshaping or laser ablating a surface of the optical lens.
 137. The methodof claim 41, wherein the method of making an optical lens comprisesforming at least one of a spherical, aspheric, single vision, bifocals,multifocal, progressive addition lens, atoric, or contact lens.